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Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Pumps:
Failure Modes and Ways to
Investigate the Cause

Dr. Juergen Weinerth


Friatec - Rheinhuette GmbH & Co. KG
Rheingaustrasse 96 98
65203 Wiesbaden, Germany
Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

FRIATEC-Rheinhtte GmbH & Co.KG


Rheingaustrae 96-98
D-65203 Wiesbaden
Germany

Founded in 1857 as an iron foundry

Tel.: +49 - (0) 611 - 604 - 0


Fax: +49 - (0) 611 - 604 - 328

Webpage: www.rheinhuette.de
Email: info@rheinhuette.de

24h Service: +49 - (0) 172 -7 25 98 51


Email service:
service@rheinhuette.de

Employees: 280
Turnover: EURO 42 Mio.
Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Standardized Magnetic drive Chemical pumps in Liquid ring


chemical pumps pumps heavy duty design vacuum pump

Circulation pumps Vertical chemical


pumps
Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Quote from Hans-Jrgen Bittermann


of Process Technologies:

Wrong operation and wrong selection


causes 90 to 95 per cent of pump failures!
Problems can only be avoided if it is
understood what caused them!
17.12.2007
Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Case Examples

Broken shaft at the coupling end of a vertical pump

Damaged submerged bearings of a vertical pump

Cracked mechanical seal of a axial flow propeller pump

Abnormal increased spare part consumption

Some more pictures...


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Wrong Operation

Broken Shaft at the Coupling End of a Vertical Pump


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Vertical Pump
for Hot Sulphuric
Acid

QPump = 600m/h
H = 30m

99,5% H2SO4
T = 220C
Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Complete Metallurgical Analysis of the Shaft


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Wrong Process Operation

Damaged submerged bearings of a vertical pump


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Vertical Pump
for Ammonium Nitrate
Solution

QPump = 55m/h
H = 39m
T = 157C
NPSHA = 3,5m
NPSHR = 3,0m
Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Incorrect Operating Data

Cracked Mechanical Seal of


an Axial Flow Propeller Pump
Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Axial Flow Propeller Pump QPump = 6000m/h


DN 700 for 9% Phosphoric H = 7m
Acid T = 130C
Material Alloy 825 (2.4858) P = 13 bar
Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Information from the customer:


-Propeller did not turn anymore
-Leackage at the mechanical seal

After site inspection:


-Cracked seal ring on atmospheric side
-Pump has to be operated at 170C!
Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Abnormal High Spare Part Consumption


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Fertilizer Plant in Norway


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Various horizontal heavy duty chemical


pumps

Nitric and
Phosphoric Acid

T up to 135C

Pumps have been running over 10 years, since 2 years increased


spare part consumption
Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Step 1: List of the 5 Items with the highest spare part consumtion
(according to the customer)
Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Step 2: Preparation of a specific questionnaire sheet


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Step 3: Collect information on the plant site

Information such as:

Serial-Number
Installed Impeller Diameter
Information Regarding the Fluid
Current Operating Conditions
Pipe Layout
Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Step 4: Analysis of the information

Analysis:

Original Data Sheet


Compare the Provided
Information
Analysis of the Duty
Point
Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Step 5: Current and differential pressure measurements


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Step 6: Analysis of the result and plant visit


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth

Some more Pictures...


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth


Pumps: Failure Modes and Ways to Investigate the Cause

AIChE Clearwater Convention 2009; Dr. Jrgen Weinerth